Magnetic sensor component and assembly

ABSTRACT

A sensor comprises a housing; and a lead frame comprising at least three elongated leads having an exterior portion extending from the housing; and a magnetic sensor circuit disposed in the housing, and connected to the lead frame. The housing comprises two recesses arranged on two opposite sides of the housing for allowing the sensor to be mounted to a support. The lead frame may further comprise a plurality of tabs disposed between the elongated leads, for use as test pins. A component assembly comprising said sensor mounted on a support between deformable protrusions. A method of making said component assembly, comprising the step of positioning said component on the support between said protrusions, and deforming said protrusions such that they are at least partially disposed within the recesses.

FIELD OF THE INVENTION

The present invention relates to an electronic component with a magneticsensor circuit, having provisions for accurate positioning of saidcomponent on a support.

BACKGROUND OF THE INVENTION

Sensors are widely used in electronic devices to measure attributes ofthe environment and report a measured signal value. In manyapplications, the exact location of the sensor within the sensor systemis an important element of the overall sensor system.

Some conventional electronic devices assembled on printed circuit boardscomprise leads (electrical connection pins) extending from a devicehousing. An electronic circuit, for example an integrated circuit, isdisposed in the housing and conventionally adhered to a lead frame withleads extending through the housing to provide electrical connectionsexterior to the housing to the integrated circuit within the housing.Contacts on the integrated circuit die are electrically connected to theleads with wire bonds inside the housing. The exterior portion of theleads extending from the housing can be inserted into holes in theprinted circuit board or in a socket with socket pins inserted intoholes in the printed circuit board. For example, dual inline packages(DIPs) and sockets having two rows of connection pins are commonly used,as described in U.S. Pat. No. 4,540,226.

Printed circuit boards frequently include connectors soldered into holesto provide access to the devices on the printed circuit boards (see, forexample U.S. Pat. No. 8,480,411). In other applications, multipleboards, for example daughter cards are sometimes stacked together, forexample as disclosed in U.S. Pat. Nos. 5,890,281 and 7,220,135.

In more recent years, surface-mount packages and assembly techniqueshave dispensed with connection pins and simply rely on electricalconnections provided on the housing and positioned on a printed circuitboard. The electrical connections are subsequent soldered to circuitboard contact pads to electrically connect and locate the surface-mountelectronic devices on the circuit board.

One method used to locate devices with respect to a surface uses guidepins. For example, U.S. Pat. No. 5,978,229 describes guide pinspositioned in the corners of a socket that mate with non-standard holeson a circuit board. A related method is used to stack and electricallyconnect integrated circuits. Each circuit has projecting pins on thebottom and receiving holes on the top, as disclosed in U.S. Pat. Nos.7,880,291 and 6,476,476.

These prior-art techniques do not always provide the precision neededfor locating electronic devices, such as magnetic sensors, in atwo-dimensional or three-dimensional space within an electronic system.Furthermore, prior-art techniques do not always provide accurate z-axislocation (orthogonal to the typical x and y dimensions defining thesurface of a printed circuit board) and are not necessarily suitable forsystems in which the electronic devices are not disposed on a printedcircuit board.

There is a need, therefore, for alternative positioning methods andstructures for electronic devices within electronic systems.

SUMMARY OF THE INVENTION

It is an aim of the present invention to provide a sensor which can beaccurately positioned, and to provide a component assembly comprisingsaid sensor, and a method of making said component assembly.

It is an aim of embodiments of the present invention to provide such asensor which can be mounted in a manner where movements in any directionis blocked.

It is an aim of embodiments of the present invention to provide such asensor which can be mounted in a manner where movement in any directionis block and which is more compact than existing solutions.

It is an aim of embodiments of the present invention to provide asensor, which has provisions for improved testing without negativelyinfluencing its compactness.

It is an aim of embodiments of the present invention to provide a sensorcomponent, which has provisions for improved testing, while usingstandard dimensions of the leads required during normal operation, suchthat it can be produced and/or handled by standard tools.

These and other objects are accomplished by a sensor, and a componentassembly, and a method according to embodiments of the presentinvention.

In a first aspect, the present invention provides a component, more inparticular, a sensor, comprising: a housing; a lead frame comprising atleast three elongated leads having an exterior portion extending fromthe housing; a magnetic sensor circuit disposed in the housing, andconnected to the lead frame; the housing comprising two (and preferablyonly two) recesses arranged on two opposite sides of the housing forallowing the component to be mounted by heat-stacking.

It is an advantage of providing a housing with at least two recesses,because this allows to precisely position the component by means ofthese recesses (e.g. by heat staking), and at the same time to firmlyclamp the component at and by means of these recesses.

It is a particular advantage of using recesses (as opposed to clampingside walls without recesses) that the risk of shifting in a directionparallel to these walls is eliminated.

The component may further comprise at least one passive electricalcomponent (such as e.g. a capacitor and/or a resistor and/or a diode)also embedded inside the housing.

Preferably the lead frame is exposed only on one side, (namely at theside where the leads extend from the housing).

In an embodiment, the recesses are located at a predefined distanceabove the lead frame, and overlap at least a portion of the lead framesurface.

The predefined distance may be at least 0.2 mm, which is sufficient toguarantee that the lead frame is not exposed.

With the “recesses are overlapping at least a portion of the lead frame”is meant that a perpendicular projection of the recesses onto the planecontaining the lead frame overlaps with a portion of the lead frame.

It is an advantage that the recesses are located at a predefinednon-zero distance above the lead frame. This offers the advantage thatsuch lead frame is not exposed to the environment at this location,thereby reducing the risk of corrosion or contamination of the magneticsensor circuit and/or other components in the housing.

It is an advantage if the recesses are overlapping at least a (metallic)portion of the lead frame, because this allows to more accuratelyposition and more firmly clamp the component (as compared to a clampingforce exerted at the top of the molding package further away from thelead frame).

In an embodiment, the recesses have a shape comprising a bottom portionsubstantially parallel to the lead frame.

The bottom portion may be located at substantially half the height ofthe housing. This offers the huge advantage that (after heat stacking)movement in three dimensions is blocked, in contrast to for examplerecesses which extend over the full height of the component.

In an embodiment, the recesses have a frusto-conical wall portion or acylindrical wall portion.

This may offer the advantage that the component will auto-align whenexerting a downward force above the two recesses when mounting thecomponent (e.g. by using heat staking).

In an embodiment, the housing comprises only two recesses located on twoopposite sides of the component, and the lead frame is only exposed onone side of the housing, (namely at the side) where the leads extendfrom the housing.

This offers the advantage that less material is required, and that thecomponent can be more compact, since the lead frame does not need toextend at the side opposite leads, and thus that the receiving zone thataccommodates the component can be made smaller.

In an embodiment, the exterior portion of the elongated leads comprisesa proximal portion having a first width, and a distal portion having asecond width, the first width being smaller than the second width; andthe lead frame further comprises a plurality of tabs or pins extendingfrom the housing, each tab or pin being located substantially halfwaybetween pairs of adjacent elongated leads, and having an exterior lengthsmaller than an exterior length of the proximal portions of theelongated leads and/or having an exterior width smaller than the firstwidth of the proximal portions of the elongated leads.

It is an advantage that the elongated leads have proximal portions(adjacent the housing) with a reduced width, because this allows toprovide additional test-pins between adjacent proximal portions, whilemaintaining as much as possible typical or standard mechanicaldimensions and/or tolerances of the lead frame and the leads.

Such tabs or pens or pins are ideal for use as test pins, e.g. to allowmeasurement of signals of the circuit, without needing the sizes andtolerances typically required for soldering.

It is an advantage of such component that it has a plurality of tabs orpens or pins which can be connected to the circuit and which can be usedas test pins, without requiring a larger package. This offers the bestof both worlds: low cost due to smaller package (than would be needed ifonly elongated leads were used), and improved testability.

It is an advantage of this embodiment that it provides a component witha compact package with additional contacts.

According to a second aspect, the present invention also provides acomponent assembly, comprising: a support having a receiving zone and atleast two deformable protrusions adjacent the receiving zone; and asensor according to the first aspect, disposed on or over the supportwithin the receiving zone between said protrusions such that therecesses are adjacent said protrusions; and wherein the protrusions areat least partially disposed within the recesses.

It is an advantage of using deformable protrusions, because it allowsthe component to be fixed to the support without additional materialsupply (e.g. a resin). This may greatly simplify the mounting process.The protrusions may comprise or consist of a thermoplastic and/or ametal and/or a metal alloy.

In embodiments, the support is a printed circuit board.

In embodiments, the support is not a printed circuit board.

In embodiments, the support is a plastic support.

In embodiments, the support is a plastic support without conductivetracks.

In an embodiment, the component assembly further comprises at least onepassive electrical component; said passive electrical component beingcomprised inside the housing of the component.

The at least one passive electrical component may be or comprise acapacitor and/or a resistor and/or a diode.

Preferably the component containing the magnetic sensor circuit is theonly component mounted on the support, and all passive electricalcomponents (if present) which would normally be mounted on a PCB, arenow integrated inside said component housing. This is a very compactsolution, and allows the assembly to contain a sensor and passivecomponents, however without requiring that these passive components aremounted and electrically interconnected on the support.

According to a third aspect, the present invention also provides amethod of producing a component assembly, comprising the steps of: a)providing a sensor according to the first aspect; b) providing a supporthaving a receiving zone and at least two deformable protrusions adjacentthe receiving zone; and c) disposing the sensor on or over the supportwithin the receiving zone between said protrusions such that therecesses are adjacent said protrusions; and d) deforming the protrusionssuch that the protrusions are at least partially disposed within therecesses, thereby aligning and clamping the sensor.

It is an advantage that the protrusions and the corresponding (ormating) recesses provide both an aligning function and a fixationfunction.

According to a fourth aspect, the present invention also provides asensor, optionally but not necessarily having the features of a sensoraccording to the first aspect, the sensor comprising: a housing; acircuit disposed in the housing; a lead frame comprising at least afirst elongated lead, and a second elongated lead substantially parallelto the first elongated lead, each of the first and second elongated leadhaving an exterior portion extending from the housing; the firstelongated lead comprising a first alignment hole, and the secondelongated lead comprising a second alignment hole, each alignment holeconfigured to receive a respective positioning pin.

It is an advantage of such component that it can be precisely positionedand/or firmly connected to for example a printed circuit board, by meansof the alignment holes.

It is an advantage of such component that the alignment holes can alsobe used for load bearing purposes, for example when the component ismounted on a printed circuit board subject to vibrations. In this way,the risk that the component moves or shifts over time, or that thesoldering of the leads breaks, is substantially eliminated.

It is an advantage that the alignment holes are provided in the leads,because in this way standard package dimensions and tooling (e.g. forproducing the package and/or for pick and placement) can be used, orthey require only minimal changes.

In an embodiment, the exterior portion of each of the first and secondelongated lead comprises a proximal portion having a first width, and adistal portion having a second width larger than the first width, and acentral portion having a third width larger than the first width; andwherein the central portion of the first elongated lead comprises thefirst alignment hole, and the central portion of the second elongatedlead comprises the second alignment hole.

The width of the central portion may be smaller than, equal to, orlarger than the second width.

It is an advantage of providing the alignment holes in the centralportion, because this portion is closer to the housing than the distalportions (which are typically soldered), thus mounting tolerances can beimproved.

It is an advantage that the elongated leads have three different widths,because it allows to provide both alignment holes in the elongated leadsproper, and allows to provide additional test-pins between two adjacentproximal portions, while maintaining the mechanical tolerances of thelead frame.

In an embodiment, the lead frame further comprises a plurality of tabsextending from the housing, each tab located substantially halfwaybetween pairs of adjacent elongated leads.

Such tabs are ideal for use as test pins, to allow measurement ofsignals of the circuit, without needing the sizes and tolerancestypically required for guaranteed soldering.

It is an advantage of such component that it has a plurality of tabswhich can be connected to the circuit and which can be used as testpins, without requiring a larger package. This offers the best of bothworlds: low cost due to smaller package (than would be needed if onlyelongated leads were used), and improved testability.

It is an advantage of this embodiment that it provides a component witha compact package with additional contacts.

Preferably, each tab has a width smaller than the first width of theproximal portion of the elongated leads, and smaller than the secondwidth of the distal portion of the elongated leads.

Preferably, each tab has an exterior length smaller than an exteriorlength of the proximal portions.

With “exterior length” is meant the length of the portion exterior tothe housing.

In the example of FIG. 3A, the exterior length of the proximal portionsis equal to about 1.5 mm, and the exterior length of the tabs is equalto about 0.7 mm.

In an embodiment, the lead frame comprises only three elongated leadsand only one or only two tabs.

In an embodiment, the lead frame comprises only five elongated leads andonly one or only two or only three or only four tabs.

In an embodiment, the exterior length of the tabs is smaller than 1.0mm.

In an embodiment, the width of the tabs is a value in the range from 0.2to 0.4 mm.

It is an advantage of such tabs that they occupy only minimal space, andthus allow sufficient distance from the leads, which is good for EMI andEMC.

This also reduces the risk of making a short circuit between the tab andthe adjacent elongated lead when measuring a signal on the tab using forexample a probe of an oscilloscope.

The distance between center lines of proximal portions of adjacentelongated leads may be equal to about 2.5 mm, and/or a distance betweencenter lines of distal portions of adjacent leads may be equal to about2.5 mm, and/or a distance between centers of adjacent alignment holesmay be equal to about 2.3 mm.

The first width (46) of the proximal portions may be a value in therange from 0.5 mm to 0.7 mm.

The third width (44) of the central portions may be a value in the rangefrom 1.1 to 1.3 mm.

The first width 46 of the proximal portion may be equal to about 0.6 mm.

The second width 42 of the distal portion may be equal to about 0.8 mm.

The third width 44 of the central portion may be equal to about 1.2 mm.

In an embodiment, each of the first and second elongated leads iselectrically connected to the circuit.

In an embodiment, at least one of said tabs or pens or pins iselectrically connected to the circuit.

In an embodiment, each of said tabs is electrically connected to thecircuit.

In an embodiment, each of said first and second elongated leads furthercomprise at least two alignment protrusions extending transversely fromsaid leads.

This may further improve positioning accuracy. These protrusions mayengage with mating recesses or openings in a printed circuit board, forexample.

The two alignment protrusions preferably extend transversely from thecentral portion of the respective elongated leads.

In an embodiment, the circuit comprises at least one discrete passivecomponent.

In an embodiment, the circuit comprises a magnetic sensor circuit.

According to a fifth aspect, the present invention also provides acomponent assembly, comprising: a support having a receiving zone, andat least a first and a second positioning pin disposed on and protrudingfrom the support in the receiving zone; and a sensor according to thefourth aspect, disposed on or over the support within the receivingzone, wherein the first positioning pin is disposed within the firstalignment hole, and the second positioning pin is disposed within thesecond alignment hole.

It is an advantage of using deformable protrusions, because it allowsthe component to be fixed to the support without additional materialsupply (e.g. resin).

The protrusions may comprise or consist of a thermoplastic and/or ametal and/or a metal alloy.

In embodiments, the support is not a printed circuit board.

In embodiments, the support is a plastic support.

In embodiments, the support is a plastic support without conductivetracks.

In an embodiment, a portion of the positioning pin is disposed over aportion of the elongated lead adjacent the alignment hole.

The positioning pin may for example be bend or otherwise deformed.

According to a sixth aspect, the present invention also provides amethod of making a component assembly, comprising the steps: providing asensor according to the fourth aspect; providing a support with areceiving zone and a first and a second positioning pin disposed on andprotruding from the support in the receiving zone; and disposing thesensor on or over the support with the first positioning pin locatedwithin the first alignment hole of the sensor component, and with thesecond positioning pin located within the second alignment hole of thecomponent.

In an embodiment, the method comprises: bending or deforming one or bothof the first and second positioning pin so that at least a portion ofthe positioning pin is located over a portion of the elongated leadadjacent the alignment hole.

It is explicitly pointed out that features of the first embodiment andthe fourth embodiment can be combined, and that features of the secondand fifth embodiment can be combined, and that features of the third andsixth embodiment can be combined.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, aspects, features, and advantages ofthe present disclosure will become more apparent and better understoodby referring to the following description taken in conjunction with theaccompanying drawings, in which:

FIG. 1 to FIG. 10 are mainly intended to illustrate a sensor componenthaving leads with holes.

FIG. 1 is a perspective view of illustrative embodiments of the presentinvention;

FIG. 2 is a top view of illustrative embodiments of the presentinvention corresponding to FIG. 1;

FIG. 3A is a top view, and FIG. 3B is a side view of illustrativeembodiments of the present invention corresponding to FIG. 1;

FIG. 4 is a perspective view of illustrative embodiments of the presentinvention having a component with three leads, each lead comprising onealignment hole, disposed on a support with three correspondingpositioning pins;

FIG. 5 is a perspective view of illustrative embodiments of the presentinvention having a component with one lead comprising two alignmentholes and one lead with no alignment holes disposed on a support withtwo positioning pins disposed within the two alignment holes;

FIG. 6A is a perspective view according to illustrative embodiments ofthe present invention comprising a support with positioning pins andwires;

FIG. 6B is a schematic side view according to illustrative embodimentsof the present invention comprising a support with positioning pins andelectrically connecting wire cables;

FIG. 7 is a schematic side view according to illustrative embodiments ofthe present invention comprising positioning pins providing z-axislocation;

FIG. 8 is a schematic side view according to illustrative embodiments ofthe present invention comprising bent positioning pins;

FIG. 9 is a schematic side view according to illustrative embodiments ofthe present invention comprising deformed positioning pins; and

FIG. 10 is a flow diagram of illustrative methods of the presentinvention.

FIG. 11 to FIG. 18 are mainly intended to illustrate a sensor componenthaving a housing with recesses.

FIG. 11 is a variant of FIG. 2, and shows another exemplary componentaccording to an embodiment of the present invention.

FIG. 12 is a variant of FIG. 3A, and shows a top view of the componentof FIG. 11 without the housing, for illustrative purposes.

FIG. 13 shows the component of FIG. 11 in top view.

FIG. 14 shows the component of FIG. 13 in front view.

FIG. 15 shows the component of FIG. 11 and an exemplary supportcomprising two protrusions for holding said component.

FIG. 16 shows a component assembly comprising the support and thecomponent of FIG. 15, according to an embodiment of the presentinvention.

FIG. 17 shows the component of FIG. 11 and another exemplary supportcomprising two beam-shaped protrusions for holding said component.

FIG. 18 illustrates a method of producing a component assembly,according to an embodiment of the present invention.

The features and advantages of the present disclosure will become moreapparent from the detailed description set forth below when taken inconjunction with the drawings, in which like reference charactersidentify corresponding elements throughout. In the drawings, likereference numbers generally indicate identical, functionally similar,and/or structurally similar elements. The figures are not necessarilydrawn to scale.

DETAILED DESCRIPTION OF THE INVENTION

Electronics manufacturing processes typically pick-and-place electroniccomponents, such as integrated circuits, onto a substrate such as aprinted-circuit board or into a test fixture. However, such placementprocesses have a limited positional accuracy and the actual position ofthe integrated circuit on the printed circuit board or in the testfixture can vary somewhat. Embodiments of the present invention canprovide improved positioning of electronic devices in low-coststructures that are easy to make and adapt to a wide variety ofcircumstances and that provide simple electrical connections to theelectronic device.

The cost of electronic components is largely determined by its package,and the choice of package is often dictated by the number of externalconnections. There is often a tradeoff to be made between a largepackage with a large number of pins, with good testability but a highercost of the component and requiring more space, versus a smaller packagewith a smaller number of pins, with reduced testability, but a lowercost, and requiring less space.

Referring to FIG. 1 in perspective view, FIG. 2 in a top view, and FIG.3A and FIG. 3B as top and side views of a design drawing, in someembodiments of the present invention a component 10 comprises a housing12, a circuit 18 disposed in the housing 12, one or more leads 14 eachhaving an exterior portion 15 extending from the housing 12, and atleast two alignment holes 16. Unless explicitly mentioned otherwise, theterm “component” actually means a “sensor” or “sensor chip”.

More in particular, the component 10 shown in FIG. 1 comprises threeelongated leads 14A, including a first elongated lead with a firstalignment hole, and a second elongated lead comprising a secondalignment hole, and a third elongated lead comprising a third alignmenthole. The elongated leads are parallel.

The alignment holes 16 are disposed in the exterior portion 15 of theleads 14A and are configured to receive a positioning pin 24 (examplesof which are shown in FIG. 4 to FIG. 9).

Circuit 18 can be an electronic circuit, for example an integratedcircuit, disposed in the housing 12 and electrically connected with wirebonds to an interior portion of the leads 14 located inside the housing12. Circuit 18 can be an analog circuit, a digital circuit, or a mixedsignal circuit and can include both integrated and discrete components,for example including a discrete passive component 19 such as a resistoror a capacitor or a diode (shown in FIG. 2). Circuit 18 can be a sensorsuch as a magnetic sensor or position sensor. The response provided bysuch magnetic or position sensor can be very dependent on the preciselocation of the sensor, and the location of the circuit 18 is importantto the proper or accurate functioning of the component 10. Moreover,fixing the position of the leads 14 provides improved positioningaccuracy compared to prior-art techniques of locating the housing orpackage of an integrated circuit, for example for a molded package orhousing.

Housing 12 can serve as a body of the component 10 that may have acavity in which a semiconductor substrate and any discrete componentsare disposed and electrically connected. The semiconductor substrate maycomprise an integrated circuit die formed in, on, or as a part of thesemiconductor substrate. The elongated leads 14A may be electricallyconnected to the integrated circuit die and/or to the passivecomponent(s) 19 via wire bonds 17. Housing 12 can be, for example, aceramic or plastic package, as is known in the integrated circuitindustry.

Leads 14 are typically also referred to as “fingers” or “pins” or“connection pins” and can serve as electrical connections to the circuit18. Leads 14 can be electrically conductive and can comprise metal or ametal alloy, for example comprising copper, aluminum, tin, silver, goldor other metals and can be formed into a variety of shapes for exampleby stamping or die cutting or other metal-forming methods known in theart. Similarly, alignment holes 16 in leads 14 can be formed bystamping, die cutting, molding or other known methods. Leads 14 can becoated or layered. Leads 14 can have different lengths, shapes, and maybe connected to different elements of the component 10, for example todifferent contact pads of circuit 18.

In some embodiments of the present invention, at least two of the leads14 (e.g. a first and a second lead) are electrically connected leads14A, electrically connected to the circuit 18, and an alignment hole 16is disposed in each of the at least two leads 14A. In the exemplaryembodiment of FIG. 2 the component 10 has three elongated leads, andeach of these three leads has an alignment hole, but that is notabsolutely required. It suffices that two of the leads, preferably thetwo outer leads, have an alignment hole. The alignment hole in themiddle lead me be omitted.

In some embodiments (see for example FIG. 4), one or more of the leads14 are disconnected leads 14B that are not electrically connected to thecircuit 18, but may also have an alignment hole 16.

In some embodiments, a lead 14 can comprise multiple alignment holes 16.For example, FIG. 5 illustrates an embodiment in which one connectedlead 14A has two alignment holes 16, and another connected lead 14A hasno alignment holes 16.

In other embodiments, a component 10 can have any combination ofconnected or disconnected leads 14A, 14B each with no alignment holes16, one alignment hole 16, or two or more alignment holes 16.

The embodiment of FIG. 2 illustrates a component with three connectedleads 14A each with one alignment hole 16.

In various embodiments of the present invention and referring to FIG. 1and FIG. 2, the elongated leads 14 may have multiple portions withdifferent widths. For example, a proximal portion 15 a having a firstwidth 46, and a distal portion 15 c having a second width 42, and acentral portion 15 b having a third width 44. In preferred embodiments,the width 46 of the proximal portion is smaller than the width 42 of thedistal portion, and the width 46 of the proximal portion is smaller thanthe width 44 of the central portion. This makes it possible tosimultaneously obtain the following advantages: (i) to provide leadshaving distal portions 15 c with a standard spacing (e.g. about 2.5 mmbetween their center lines); and (ii) to provide central portions 15 bwith alignment holes 16; and (iii) to provide tabs 14C (also referred toherein as “second leads” or “test pins” or simply as “pins”) for use astest pins; and (iv) without requiring a package with more elongatedleads, and without having to use non-standard dimensions between theleads, as the latter may have a negative impact on the connectability ofthese leads using standard equipment.

According to some embodiments of the present invention, an exteriorportion 15 of a lead 14 has an average width 40 and the width 44 of thecentral portion 15 b of the lead 14 at the location of the alignmenthole 16 is greater than the average width 40.

In some embodiments, the width 46 of the proximal portion 15 a of thelead 14 adjacent to the housing 12 is less than the average width 40. Bydecreasing the first width 46 of the proximal portion, space can beprovided for additional connections (i.e. the tabs 14C), and byincreasing the width of the central portion 15 b of the lead 14 at thelocation of the alignment hole 16, a robust mechanical structure can beprovided.

The housing of the component 10 shown in FIG. 1 and FIG. 2 alsocomprises two recesses 13, but these are not mandatory in theembodiments shown in FIG. 1 to FIG. 10. In contrast, the embodiments ofFIG. 11 to FIG. 18 are related to the recesses 13 but do not absolutelyrequire leads with positioning holes 16.

As shown in FIG. 2 and FIG. 3, the tabs (also referred to herein as“test pins” or “pens” or “pins” or “short leads”) 14C have a fourthwidth 48 smaller than each of the first width 46, the second width 42,and the third width 44. The short leads or tabs 14C do not havealignment holes 16. The short leads 14C may provide test connections forthe component 10 without increasing the size of the component 10 or thespacing of the leads 14, in particular of the distal portions 15 cthereof.

In the embodiment shown in FIG. 1 to FIG. 3, the package has only threeelongated leads 14A and only two tabs 14C located between said leads,but the present invention is not limited hereto, and packages with onlyfive elongated leads and four tabs located in between the leads are alsoenvisioned.

Referring to FIG. 4 and FIG. 5, a component assembly 99 of the presentinvention can comprise a support 20. The support 20 can have a surface22 with a receiving zone 30 in which one or more components 10 can bedisposed, for example by pick-and-place equipment. One or morepositioning pins 24 are disposed on and protrude from the support 20 inthe receiving zone 30. A component 10 is disposed on or over the surface22 of the support 20 within the receiving zone 30.

A positioning pin 24 can be disposed within only one alignment hole 16of the component, or a positioning pin 24 can be disposed within each ofat least two alignment holes 16 of the component, or a positioning pin24 can be disposed within each alignment hole 16 of the component.

As shown in FIG. 4, the component 10 may have both connected leads 14Athat are electrically connected to the circuit 18, and disconnectedleads 14B that are not electrically connected to the circuit 18.(Connected leads 14A and disconnected leads 14B are collectivelyreferred to herein as leads 14.) Both connected leads 14A anddisconnected leads 14B may have an alignment hole 16 with a positioningpin 24 disposed in the alignment holes 16. A positioning pin 24 can be,but is not necessarily, electrically conductive and may be electricallyconnected to a lead 14.

Referring to FIG. 5, the component 10 can have connected leads 14Aelectrically connected to the circuit 18, some of which have more thanone alignment hole 16 and some of which do not have any alignment holes16. It is an advantage of this embodiment that the component 10 can beaccurately positioned by means of only one elongated lead.

A support 20 can be planar (as shown in FIG. 4 and FIG. 5) or non-planar(not shown). A support 20 can have wires 60 integrated into the support20 to form, for example, a printed circuit board or other wiring boardor wires 60 can be provided separately from the support 20. A wire 60can be electrically connected to each connected lead 14A. Referring toFIG. 6A, wires 60 can be directly connected, mechanically orelectrically, to the positioning pins 24 or leads 14, or both. Referringto FIG. 6B, wires 60 can be provided independently of the support 20,for example as cables that are electrically connected to leads 14directly (as shown) or indirectly (not shown). In some embodiments, thecable wires 60 can be directly connected to the positioning pins 24.

In various embodiments, the support 20 can comprise a resin or epoxysubstrate, a multi-layer structure, for example planar structures, acast, molded, or machined part or structure, for example comprising apolymer, metal, metal alloy, or ceramic. Likewise, the positioning pins24 can be cast, molded, or machined, or formed by etching a part orstructure. The positioning pins 24 may be electrically conductive orelectrically insulating, and may comprise a polymer, metal, metal alloy,or ceramic. The positioning pins 24 may be rigid, flexible, compliant,or ductile. A positioning pin 24 may be electrically connected to eachof, any one of, or none of the leads 14 and the wires 60.

According to embodiments of the present invention, the positioning pins24 disposed in the alignment holes 16, for example by locatingcomponents 10 on the receiving zone 30 on or over the surface 22 of thesupport 20 with the positioning pins 24 disposed in the alignment holes16 by pick-and-place equipment, serve to precisely locate the component10 with respect to the support 20 in a simple and inexpensive way thatcan be applied to a broad variety of component assembly structures. Byrequiring at least two positioning pins 24 in respective alignment holes16, the component 10 is spatially fixed in position with respect to thesupport 20 so that component 10 cannot rotate or move with respect tothe support 20. By providing alignment holes 16 in the leads 14,additional alignment or mounting structures are rendered unnecessary,for example special housing 18 and support 20 structures, so that thecomponents 10 can be smaller and take up less area of the support 20. Orstated in other words, for the particular package shown in FIG. 1 andFIG. 3, by providing alignment holes 16 in the three elongated leads 14,other structures (e.g. located at the corners of the lead frame) can beavoided, thus layout structures and existing mounting equipment canstill be used.

Referring to FIG. 7, in an embodiment the location of the component 10is controlled in the height direction or the z-axis (controlled withrespect to the distance between the surface 22 of the support 20 and thecomponent 10). The height of the component 10 with respect to thesupport 20 can be controlled with a positioning pin 24, for example byproviding a variable diameter positioning pin 28 with a variablediameter that can accept an alignment hole 16 at only certain predefinedz-axis locations or predefined heights above the support 20. Thevariable diameter may be continuous, as shown, or discontinuous, forexample with stepped structures (not shown). In the case where circuit18 is a sensor, e.g. a magnetic position sensor, the precise location ofthe sensor and any discrete passive components 19 can be important tothe proper or accurate functioning of the sensor.

In some embodiments of the present invention, after the component 10 isdisposed with positioning pins 24 in alignment holes 16, the positioningpin 24 can be deformed so that a portion of the positioning pin 24 isdisposed over a portion of the electrically conductive exterior portion15 of the lead 14 that is not the alignment hole 16 in the lead 14, e.g.adjacent the alignment hole. For example, as shown in FIG. 8, thepositioning pin 24 is deformed by bending the positioning pin 24 so thata portion of the bent deformed positioning pin 26 is located over anon-alignment-hole portion of the lead 14, that is over a conductiveportion of the lead 14, such as a metallic portion, and is not only overthe alignment hole 16.

In the example of FIG. 9, the positioning pin 24 is deformed byflattening the positioning pin 24 so that a portion of the flatteneddeformed positioning pin 26 is located over a metal portion of the lead14, adjacent the alignment-hole 16.

Positioning pins 24 may be mechanically deformed, e.g. plastically orpermanently deformed (in contrast to elastically deformed), for exampleby striking the positioning pin 24 with a hammer on the side of thepositioning pin 24 to bend it or on the top of the positioning pin 24 toflatten it. By deforming a positioning pin 24 within an alignment hole16 of a lead 14, a component 10 is held in place and is not readilyremoved from the positioning pin 24 and support 20.

In other or additional embodiments of the present invention, the wire60, positioning pin 24 and lead 14 may be soldered together with solder50 to form an electrical connection electrically connecting the circuit18 to the wires 60 and the positioning pin 24 through the lead 14, ifthe lead 14 is a connected, electrically conductive lead 14A and thepositioning pin 24 is electrically conductive, so that the positioningpin 24 is electrically connected to the lead 14 in whose alignment hole16 the positioning pin 24 is disposed.

Referring to the flow-chart of FIG. 10, a component assembly 99 of thepresent invention can be constructed by providing a component 10 asdescribed above in step 100, for example using photolithographic methodsto form a circuit 18, for example comprising an integrated circuit (IC)and optionally one or more discrete passive or active circuit elements,assembling the IC and circuit elements onto a substrate, for example asemiconductor, glass, or ceramic substrate, and interconnecting themwith any combination of wire bond or photolithographic methods and toolsto form an assembled circuit 18. Leads 14 are constructed using metalforming methods and integrated into a housing 12 into which theassembled circuit 18 is disposed and electrically connected to theinterior portion of the leads 14 inside the housing 12 using, forexample, wire bonding methods. The housing 12 is then enclosed andencapsulated as desired.

A support 20 with one or more protruding positioning pins 24 is providedin step 110, for example by molding or laminating layers of resin orcasting, molding, or machining materials such as ceramics, metals, ormetal alloys into a desired shape, the shape providing a surface 22 withpositioning pins 24 protruding from a surface 22 of the support 20within a pre-determined receiving zone 30 for locating a component 10.In some embodiments, positioning pins 24 are partly inserted inthrough-holes of a PCB, and optionally soldered at the bottom side.

In step 120, a component 10 is disposed on a support 20 such that thealignment holes 16 of the component 10 are aligned with the positioningpins 24 of the support, and the positioning pins 24 are inserted intothe alignment holes 16 (or vice versa), for example using pick-and-placeequipment from a tape-and-reel package.

Once the component 10 is properly disposed in the receiving zone 30 ofthe support 20, in optional step 130 the positioning pins 24 can beoptionally deformed to firmly, rigidly, permanently or irreversibly holdthe component 10 in position with respect to the support 20. Multiplepositioning pins 24 may be bent in different directions or deformed towiden the position pins 24, thus preventing each lead 14 from escapingthe corresponding positioning pin 24. The deformation may locate atleast a portion of the positioning pin 24 over a metal portion of thelead 14, adjacent the alignment hole 16. The deformation can providemechanical robustness to the component assembly 99 and prevent thedifferential movement of the component 10 and the support 20, forexample as a result of vibration.

In optional step 140, the positioning pins 24 may optionally be solderedto the leads 14, for example to provide electrical connections betweenthe lead 14 and the wire 60, and optionally the positioning pin 24. Thesolder 50 can also provide additional mechanical strength to thephysical connection between the component 10 and the support 20.

In operation, power may be provided to a wire 60 and hence to a lead 14and circuit 18. Signals from the circuit 18 are sent through anotherlead 14 and wire 60 to a controller (not shown in the figures).

FIG. 11 to FIG. 14 show another exemplary component 10 according to anembodiment of the present invention. The component of FIG. 11 to FIG. 14can be seen as a variant of FIG. 2. The main differences being that thecomponent of FIG. 11 to FIG. 14 does not necessarily comprise alignmentholes, and that the elongated leads 14A do not necessarily contain threesegments having three different widths, but may contain two segmentshaving two different widths. Other features described above may also beapplicable here. The main focus of the embodiments of FIG. 11 to FIG. 18is related to the recesses 13, as will be discussed further.

The component 10 shown in FIG. 11 comprises a housing 12, and a leadframe, and a magnetic sensor circuit 18. The housing may comprise athermoset plastic material. The lead frame comprises at least threeelongated leads 14A having an exterior portion 15 extending from thehousing 12. The magnetic sensor circuit 18 may comprise at least oneHall element, or a plurality of Hall elements, and is disposed in thehousing, and is connected to the lead frame. The housing 12 comprisestwo recesses 13 arranged on opposite sides of the housing. The recessesmay have a shape comprising a bottom portion substantially parallel tothe lead frame. The recesses may have a frusto-conical wall portion or acylindrical wall portion. The component 10 of FIG. 11 has threeelongated leads 14A, but the invention is not limited thereto, and inalternative embodiments, the component 10 has five elongated leads 14A.

FIG. 12 shows a top view of the component of FIG. 11 without thehousing, for illustrative purposes.

The component of FIG. 12 has three elongated leads 14A. The leads 14A ofthe component 10 shown in FIG. 12 do not have alignment holes 16, andtherefore also do not require a central portion as described above.

The component 10 may comprise a plurality of tabs or test pins 14Clocated substantially halfway between proximal portions of the elongatedleads 14A. These tabs or test pins 14C may have very small dimensions,for example have an external length of about 0.7 mm and an externalwidth of about 0.3 mm, while allowing distal portions of the elongatedleads to be spaced apart by about 2.5 mm from centerline to centerline.If the test pins are present (as shown in FIG. 12), the elongated leads14A preferably have a proximal segment having a first width 46, and adistal segment having a second width 42 larger than the first width 46.If the test pins 14C are not present, the elongated leads 14A may have aconstant width.

The recesses 13 of the housing 12 may overlap at least a portion 14D ofthe lead frame and/or of the elongated leads in an overlapping area 11.An inner portion of the elongated leads 14A may be broadened or widenedto create such an overlap (see FIG. 12). Optionally, the lead frameportion containing the magnetic sensor circuit 18 contains theoverlapping zones 11 (not shown).

FIG. 13 shows the component of FIG. 11 in top view, including thehousing. The component 10 of FIG. 13 has only two recesses 13, but thepresent invention is not limited thereto, and alternative embodimentsmay comprise three recesses, namely the two recesses shown in FIG. 13plus an additional recess at the right side of FIG. 13, opposite theside where the leads 14 extend from the housing.

FIG. 14 shows the component of FIG. 13 in front view. A bottom of therecesses 13 of the housing 12 may be located at a predefined distance“d” (see FIG. 14) above the lead frame (e.g. at least 0.5 mm). Thus, thelead frame is not exposed at this location, but is covered for exampleby a plastic molding material, even at the location of the recesses 13.

FIG. 15 shows the component of FIG. 11 and an exemplary support 20comprising two protrusions 32 for holding said component 10. The support20 may comprise or mainly comprise or consists of a plastic material.The protrusions 32 may have any suitable shape, e.g. substantiallycylindrical. The support 20 has a receiving zone 30 between the twoprotrusions for accommodating the component 10. The distance between theprotrusions 32 is preferably only marginally larger than an outerdimension of the housing 12. The protrusions 32 may be formed integrallywith the rest of the support 20. The protrusions are made of adeformable material, e.g. thermoplastic or metal or a metal alloy.

FIG. 16 shows a component assembly 99 comprising the support 20 and thecomponent 10 of FIG. 15. The protrusions 32 are deformed so as to alignthe component 10 and so as to clamp the component 10 on the support 20.

FIG. 17 shows the component of FIG. 11 and another exemplary supportcomprising two beam shaped protrusions 32 for holding said component 10.

The protrusions 32 are preferably deformed against an inclined wall ofthe component 10, and in such a manner that at least a portion of theprotrusions enters the space defined by the recesses 13, for clampingthe component 10. A component assembly (not shown) where the componentis clamped in this manner, is also envisioned.

FIG. 18 illustrates a method 1800 of producing a component assembly 99,such as the one shown in FIG. 16. The method 1800 comprises thefollowing steps:

-   -   a) providing 1801 a component 10 with recesses 13, for example        as shown in FIG. 11 to FIG. 17;    -   b) providing a support 20 having a receiving zone 30 and at        least two deformable protrusions 32, for example as shown in        FIG. 15 and FIG. 17;    -   c) disposing 1803 the component 10 on or over the support 20        within the receiving zone 30 between said protrusions 32 such        that the recesses 13 of the component are located adjacent said        protrusions 32 of the support 20; and    -   d) deforming the protrusions 32 such that the protrusions are at        least partially disposed within the recesses 13 (or stated in        other words: such that at least a portion of the material of the        protrusions has entered the recess), thereby aligning and        clamping the component 10 on the support 20.

As is understood by those skilled in the art, the terms “over”, “under”,“above”, “below”, “beneath”, and “on” are relative terms and can beinterchanged in reference to different orientations of the layers,elements, and substrates included in the present invention. For example,a first layer, element, or structure on a second layer, element, orstructure in some embodiments means a first layer, element, or structuredirectly on and in contact with a second layer, element, or structure.In other embodiments, a first layer, element, or element on a secondlayer, element, or structure can include another layer there between.Additionally, “on” can mean “on” or “in” or “in contact with” or“directly on.”

Having described certain embodiments, it will now become apparent to oneof skill in the art that other embodiments incorporating the concepts ofthe disclosure may be used. Therefore, the invention should not belimited to the described embodiments, but rather should be limited onlyby the spirit and scope of the following claims.

Throughout the description, where apparatus and systems are described ashaving, including, or comprising specific elements, or where processesand methods are described as having, including, or comprising specificsteps, it is contemplated that, additionally, there are apparatus, andsystems of the disclosed technology that consist essentially of, orconsist of, the recited elements, and that there are processes andmethods according to the disclosed technology that consist essentiallyof, or consist of, the recited processing steps.

It should be understood that the order of steps or order for performingcertain action is immaterial so long as the disclosed technology remainsoperable. Moreover, two or more steps or actions in some circumstancescan be conducted simultaneously. The invention has been described indetail with particular reference to certain embodiments thereof, but itwill be understood that variations and modifications can be effectedwithin the spirit and scope of the invention.

1. A sensor, comprising: a housing; a lead frame comprising at leastthree elongated leads having an exterior portion extending from thehousing; a magnetic sensor circuit disposed in the housing, andconnected to the lead frame; the housing comprising two recessesarranged on two opposite sides of the housing for allowing the sensor tobe mounted by heat-stacking.
 2. The sensor of claim 1, wherein therecesses have a shape comprising a bottom portion substantially parallelto the lead frame.
 3. The sensor of claim 1, wherein the recesses have afrusto-conical wall portion or a cylindrical wall portion.
 4. The sensorof claim 1, wherein the housing comprises only two recesses located ontwo opposite sides of the component, and wherein the lead frame is onlyexposed on one side of the housing, where the elongated leads extendfrom the housing.
 5. The sensor of claim 1, wherein the exterior portionof the elongated leads comprises a proximal portion having a firstwidth, and a distal portion having a second width, the first width beingsmaller than the second width; and wherein the lead frame furthercomprises a plurality of tabs or pins extending from the housing, eachtab or pin being located substantially halfway between pairs of adjacentelongated leads, and having an exterior length smaller than an exteriorlength of the proximal portions of the elongated leads and/or having anexterior width smaller than the first width of the proximal portions ofthe elongated leads.
 6. A component assembly, comprising: a supporthaving a receiving zone and at least two deformable protrusions adjacentthe receiving zone; and a sensor according to claim 1, disposed on orover the support within the receiving zone between said protrusions suchthat the recesses are adjacent said protrusions; and wherein theprotrusions are at least partially disposed within the recesses.
 7. Thecomponent assembly of claim 6, further comprising at least one passiveelectrical component; said passive electrical component being comprisedinside the housing of the component.
 8. A method of producing acomponent assembly, comprising the steps of: a) providing a sensoraccording to claim 1; b) providing a support having a receiving zone andat least two deformable protrusions adjacent the receiving zone; and c)disposing the sensor on or over the support within the receiving zonebetween said protrusions such that the recesses are adjacent saidprotrusions; and d) deforming the protrusions such that the protrusionsare at least partially disposed within the recesses, thereby aligningand clamping the sensor.